U.S. patent application number 15/619796 was filed with the patent office on 2017-09-28 for footwear upper with molded geometry.
The applicant listed for this patent is Under Armour, Inc.. Invention is credited to Mark Auger, Nicole Doenges, David Dombrow, Kevin Fallon.
Application Number | 20170273404 15/619796 |
Document ID | / |
Family ID | 59897093 |
Filed Date | 2017-09-28 |
United States Patent
Application |
20170273404 |
Kind Code |
A1 |
Doenges; Nicole ; et
al. |
September 28, 2017 |
FOOTWEAR UPPER WITH MOLDED GEOMETRY
Abstract
An article of footwear includes a sole structure and an upper
secured to the sole structure. The upper includes a heel section,
lateral side section, medial side section, instep and toe cage that
define an interior cavity operable to receive a foot of a wearer.
At least a portion of the upper includes a laminate, where the
laminate includes an inner layer facing the cavity, an outer layer
forming an exterior of the shoe, and an intermediate layer disposed
between inner and outer layers, the intermediate layer comprising a
reinforcing layer having a rigidity that is greater than the
rigidity of the inner and outer layers. The reinforcing layer
extends from the lateral side section to the medial side
section.
Inventors: |
Doenges; Nicole; (Baltimore,
MD) ; Auger; Mark; (Baltimore, MD) ; Fallon;
Kevin; (Portland, OR) ; Dombrow; David;
(Baltimore, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Under Armour, Inc. |
Baltimore |
MD |
US |
|
|
Family ID: |
59897093 |
Appl. No.: |
15/619796 |
Filed: |
June 12, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14458712 |
Aug 13, 2014 |
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15619796 |
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|
62348430 |
Jun 10, 2016 |
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61865384 |
Aug 13, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 23/026 20130101;
A43B 7/26 20130101; A43B 23/087 20130101; A43B 23/0235 20130101;
A43B 23/0295 20130101; A43B 23/0215 20130101; A43B 23/17
20130101 |
International
Class: |
A43B 23/02 20060101
A43B023/02 |
Claims
1. An article of footwear comprising: a sole structure; and an
upper secured to the sole structure; wherein: the upper includes a
heel section, a lateral side section, a medial side section, an
instep and a toe cage that define an interior cavity operable to
receive a foot of a wearer; and at least a portion of the upper
comprises a laminate comprising an inner layer facing the cavity,
an outer layer forming an exterior of the shoe, and an intermediate
layer disposed between inner and outer layers, the intermediate
layer comprising a reinforcing layer having a rigidity that is
greater than the rigidity of the inner and outer layers, the
reinforcing layer extending from the lateral side section to the
medial side section.
2. The article of footwear of claim 1, wherein the reinforcing
layer comprises a structural support member having a hardness value
that is greater than the hardness value of the inner and outer
layers.
3. The article of footwear of claim 2, wherein the inner and outer
layers comprise fabric materials, and the structural support member
comprises a plastic material.
4. The article of footwear of claim 3, wherein the structural
support member comprises a thermoplastic polyurethane material or
an ethylene vinyl acetate material.
5. The article of footwear of claim 3, further comprising a
plurality of intermediate layers disposed between the inner layer
and the outer layer, at least one of the intermediate layers
comprising a foam layer.
6. The article of footwear of claim 5, wherein the laminate
includes a first foam layer disposed between the structural support
member and the inner layer and a second foam layer disposed between
the structural support member and the outer layer.
7. The article of footwear of claim 3, wherein the structural
support member comprises an internal heel counter located at the
heel section of the upper.
8. The article of footwear of claim 7, wherein the internal heel
counter has a generally U-shaped configuration.
9. The article of footwear of claim 1, wherein the upper comprises
a first portion coupled with a second portion.
10. The article of footwear of claim 9, wherein the first portion
comprises a planum portion that directly covers and/or engages a
majority of a bottom side of the wearer's foot wherein the planum
portion comprises the laminate, and the second portion comprises a
dorsum portion that directly covers and/or engages a majority of an
upper side of the wearer's foot.
11. An upper for an article of footwear, the upper comprising: a
heel section, a lateral side section, a medial side section, an
instep and a toe cage that define an interior cavity operable to
receive a foot of a wearer; wherein at least a portion of the upper
comprises a laminate comprising an inner layer facing the cavity,
an outer layer forming an exterior of the upper, and an
intermediate layer disposed between the inner and outer layers, the
intermediate layer comprising a reinforcing layer having a rigidity
that is greater than the rigidity of the inner and outer
layers.
12. A method of forming an upper for an article of footwear, the
method comprising: combining a plurality of portions including a
first portion with a second portion, the plurality of portions
defining a heel section, a lateral side section, a medial side
section, an instep and a toe cage that define an interior cavity of
the upper operable to receive a foot of a wearer, wherein the first
portion is formed by a laminate, the laminate being formed by:
combining a plurality of layers together, including an inner layer
that faces the cavity with an outer layer forming an exterior of
the upper and an intermediate layer disposed between the inner and
outer layers, the intermediate layer comprising a reinforcing layer
having a rigidity that is greater than the rigidity of the inner
and outer layers.
13. The method of claim 12, wherein the reinforcing layer comprises
a structural support member having a hardness value that is greater
than the hardness value of the inner and outer layers.
14. The method of claim 12, wherein the layers are combined to form
the laminate by: combining the layers in a mold and compressing the
layers together while being heated to a temperature sufficient to
soften at least one layer so as to adhere the layers together.
15. The method of claim 14, wherein the layers are compressed
together while being heated to a temperature about 130.degree. C.
to about 200.degree. C.
16. The method of claim 14, wherein the mold includes mold parts
that compress the layers together in a shape to define a contoured
curve portion of the upper.
17. The method of claim 16, wherein the layers are compressed
within the mold to form a curved heel cup portion of the heel
section of the upper, such that the reinforcing member is formed
between the inner and outer layers as an internal heel counter of
the upper having a generally U-shaped configuration.
18. The method of claim 12, wherein the plurality of layers
includes further intermediate layers disposed between the inner
layer and the outer layer, at least one of the further intermediate
layers comprising a foam layer.
19. The method of claim 18, wherein the further intermediate layers
include a first foam layer disposed between the inner layer and the
reinforcing layer and a second foam layer disposed between the
reinforcing layer and the outer layer.
20. The method of claim 12, wherein the first portion comprises a
planum portion that directly covers and/or engages a majority of a
bottom side of the wearer's foot, and the second portion comprises
a dorsum portion that directly covers and/or engages a majority of
an upper side of the wearer's foot.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an article of footwear and,
in particular, to a running shoe.
BACKGROUND
[0002] An article of footwear such as a running shoe is designed
for comfort and durability. An article of footwear is typically
constructed from a material or a combination of materials having
insulative, moisture resistant and/or abrasion resistant
characteristics. Processes for constructing performance footwear
can be labor intensive, often requiring sophisticated and expensive
stitching and/or injection molding equipment. For example,
conventional uppers may be constructed via stitching, i.e., by
cutting material according to a pattern to form a series of
individual pieces, and then stitching the individual pieces of the
pattern together to form the upper. The end result is a shoe having
a significant number of seams. Seams, which are friction points,
are located throughout the upper and, in particular, in the heel
and bottom areas. In light of this, conventional footwear requires
an insole or other covering to hide the stitched seam along the
bottom of the upper.
[0003] Another conventional method for forming an article of
footwear is via injection. This type of footwear is designed for
harsh weather conditions (e.g. rubber boots). While generally
seamless, this type of footwear is water and vapor impermeable,
resulting in footwear lacking breathability. In the context of
athletic footwear, this process results in wearer discomfort
because airflow into and out of the shoe is prevented. Accordingly,
heat and perspiration from the wearer cannot be evacuated to the
ambient environment, resulting in wearer discomfort.
[0004] Thus, it would be desirable to provide an article of
footwear that is lightweight, breathable, and durable, but avoids
seams and/or stitches in the heel and/or footpad areas. It would
also be desirable to provide some amount of rigidity or support in
certain areas of the shoe (e.g., the heel section) while
maintaining lightweight characteristics of the footwear.
SUMMARY OF THE INVENTION
[0005] In certain embodiments, an article of footwear comprises a
sole structure and an upper secured to the sole structure. The
upper includes a heel section, a lateral side section, a medial
side section, an instep and a toe cage that cooperate to define an
interior cavity operable to receive a foot of a wearer. At least a
portion of the upper comprises a laminate comprising an inner layer
facing the cavity, an outer layer forming an exterior of the shoe,
and an intermediate layer disposed between inner and outer layers,
the intermediate layer comprising a reinforcing layer having a
rigidity that is greater than the rigidity of the inner and outer
layers. The reinforcing layer extends from the lateral side section
to the medial side section.
[0006] In other embodiments, an upper for an article of footwear
comprises a heel section, a lateral side section, a medial side
section, an instep and a toe cage that define an interior cavity
operable to receive a foot of a wearer. At least a portion of the
upper comprises a laminate comprising an inner layer facing the
cavity, an outer layer forming an exterior of the upper, and an
intermediate layer disposed between the inner and outer layers, the
intermediate layer comprising a reinforcing layer having a rigidity
that is greater than the rigidity of the inner and outer
layers.
[0007] In still further embodiments, a method of forming an upper
for an article of footwear comprises combining a plurality of
portions including a first portion with a second portion, the
plurality of portions defining a heel section, a lateral side
section, a medial side section, an instep and a toe cage that
define an interior cavity of the upper operable to receive a foot
of a wearer. The first portion is formed by a laminate, where the
laminate is formed by combining a plurality of layers together,
including an inner layer that faces the cavity with an outer layer
forming an exterior of the upper and an intermediate layer disposed
between the inner and outer layers, the intermediate layer
comprising a reinforcing layer having a rigidity that is greater
than the rigidity of the inner and outer layers.
[0008] The above and still further features and advantages of the
present invention will become apparent upon consideration of the
following detailed description of specific embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A is a rear perspective view of a portion of an
article of footwear in accordance with an embodiment of the
invention (footwear configured for a right foot).
[0010] FIG. 1B is side view in elevation of the article of footwear
shown in FIG. 1A, showing the lateral footwear side.
[0011] FIG. 1C is side view in elevation of the article of footwear
shown in FIG. 1A, showing the medial footwear side.
[0012] FIG. 1D is front view in perspective of the article of
footwear shown in FIG. 1.
[0013] FIG. 1E is rear view in elevation of a portion of the
article of footwear shown in FIG. 1A.
[0014] FIG. 1F is top view in plan of the article of footwear shown
in FIG. 1A.
[0015] FIG. 2 is a lateral side view in perspective of two main
portions of the upper for the article of footwear shown in FIG.
1.
[0016] FIG. 3 is a lateral side view in elevation of one of the two
main portions of the upper of FIG. 2.
[0017] FIG. 4 is a cross sectional view of compression molding
apparatus showing upper formation and layers of a fabric laminate
that form a portion of an upper of the article of footwear of FIG.
1A.
[0018] FIG. 5 is a flowchart illustrating an example process for
compression molding an upper with multiple layers in accordance
with the present invention.
[0019] FIG. 6 is a lateral side view in perspective of the two main
portions of the upper for the article of footwear shown in FIG. 2
and further including a plurality of internal support structures
for the upper separated from each other.
[0020] Like reference numerals have been used to identify like
elements throughout this disclosure.
DETAILED DESCRIPTION
[0021] In the following detailed description, reference is made to
the accompanying figures which form a part hereof wherein like
numerals designate like parts throughout, and in which is shown, by
way of illustration, embodiments that may be practiced. It is to be
understood that other embodiments may be utilized, and structural
or logical changes may be made without departing from the scope of
the present disclosure. Therefore, the following detailed
description is not to be taken in a limiting sense, and the scope
of embodiments is defined by the appended claims and their
equivalents.
[0022] Aspects of the disclosure are disclosed in the accompanying
description. Alternate embodiments of the present disclosure and
their equivalents may be devised without parting from the spirit or
scope of the present disclosure. It should be noted that any
discussion herein regarding "one embodiment", "an embodiment", "an
exemplary embodiment", and the like indicate that the embodiment
described may include a particular feature, structure, or
characteristic, and that such particular feature, structure, or
characteristic may not necessarily be included in every embodiment.
In addition, references to the foregoing do not necessarily
comprise a reference to the same embodiment. Finally, irrespective
of whether it is explicitly described, one of ordinary skill in the
art would readily appreciate that each of the particular features,
structures, or characteristics of the given embodiments may be
utilized in connection or combination with those of any other
embodiment discussed herein.
[0023] Various operations may be described as multiple discrete
actions or operations in turn, in a manner that is most helpful in
understanding the claimed subject matter. However, the order of
description should not be construed as to imply that these
operations are necessarily order dependent. In particular, these
operations may not be performed in the order of presentation.
Operations described may be performed in a different order than the
described embodiment. Various additional operations may be
performed and/or described operations may be omitted in additional
embodiments.
[0024] For the purposes of the present disclosure, the phrase "A
and/or B" means (A), (B), or (A and B). For the purposes of the
present disclosure, the phrase "A, B, and/or C" means (A), (B),
(C), (A and B), (A and C), (B and C), or (A, B and C).
[0025] The terms "comprising," "including," "having," and the like,
as used with respect to embodiments of the present disclosure, are
synonymous.
[0026] As described herein with reference to the example embodiment
of FIGS. 1A-3, an article of footwear 10 in accordance with the
invention includes an upper 105 coupled with a sole structure 110.
The article of footwear 10, also referred to herein as a shoe, can
be in the form of a running shoe or other type of athletic shoe.
The shoe 10 defines several regions corresponding with various
parts of a foot. Specifically, the shoe 10 defines a rear footwear
region 115 generally corresponding with the rear of the foot (e.g.,
the hindfoot including the heel and ankle areas of the foot), an
intermediate footwear region 120 disposed forward the rear region
and generally corresponding with the midfoot (e.g., the arched,
instep, and ball areas of the foot), and a forward footwear region
125 disposed forward of intermediate region and generally
corresponding with the forefoot (e.g., the toes of the foot). The
article of footwear 10 may further include a fastener 127 (e.g., a
shoe lace). The upper 105 and sole structure 110 can be formed from
any materials (described in more detail herein) suitable for their
intended purposes.
[0027] The upper 105 includes a medial side 140 (which corresponds
with the medial side of the shoe) that is oriented along the medial
or big toe side of the user's foot, a lateral side 135 (which
corresponds with the lateral side of the shoe) that is oriented
along the lateral or little toe side of the user's foot (the medial
and lateral sides being distinguished by a central, longitudinal
axis), a toe (i.e., front) end 150 (also referred to as a toe cage
or toe box) that corresponds with the toe end of the user's foot,
and a heel (i.e., rear) end 130 that corresponds with the heel of
the foot. The heel end 130 has a curved shape defining a heel cup
that generally conforms to the user's heel and extends between the
lateral and medial sides 135, 140 of the upper 105. The upper 105
further includes an instep 145 positioned between the lateral side
and the medial side, where the instep 145 extends over the instep
of the foot and generally includes a tongue 147. The fastener 127
is disposed at the instep 145.
[0028] The upper 105 defines a cavity such that, when secured to a
portion of the sole structure 110 (as described herein), the upper
receives, covers and protects the foot within the cavity.
Specifically, the heel 130, lateral side 135, medial side 140,
instep 145, and toe cage 150 cooperate to define portions of the
hindfoot section, midfoot section and forefoot section of the shoe
as well as an interior cavity into which a foot is inserted by way
of an access opening or collar 155. The collar 155 may be finished
with, e.g., fabric tape applied via adhesive. In an embodiment, a
strip of material is applied around an inside edge of collar 155 to
allow the edge of collar to be finished without a binding to reduce
fraying and/or to help collar adhere to the skin of the user. The
material may be an elastomeric and/or tacky polymer such as, but
not limited to, polyurethane, silicone, nylon, and polyester.
[0029] The sole structure 110 comprises a durable, wear-resistant
component configured to provide cushioning as the shoe 10 impacts
the ground. In certain embodiments, the sole structure 110 may
include a midsole and an outsole. In additional embodiments, the
sole structure 110 can further include an insole that is disposed
between the midsole and the upper 105 when the shoe 100 is
assembled. In other embodiments, the sole structure 110 may be a
unitary and/or one-piece structure. The sole structure includes an
upper facing side or portion that is configured to secure with the
upper and an opposing ground-facing side that defines a generally
planar surface and can further be textured and/or include
ground-engaging or traction elements (e.g., as part of an outsole
of the sole structure) to enhance traction of the shoe 10 on
different types of terrains and depending upon a particular purpose
in which the shoe is to be implemented. The ground-facing side of
the sole structure 110 can also include one or more recesses formed
therein, such as indentations or grooves extending in a lengthwise
direction of the sole structure 110 and/or transverse the
lengthwise direction of the sole structure, where the recesses can
provide a number of enhanced properties for the sole structure
(e.g., flexure/pivotal bending along grooves to enhance flexibility
of the sole structure during use). The sole structure 110 may be
formed of a single material or may be formed of a plurality of
materials. In example embodiments in which the sole structure
includes a midsole and an outsole, the midsole may be formed of one
or more materials including, without limitation, ethylene vinyl
acetate (EVA), an EVA blended with one or more of an EVA modifier,
a polyolefin block copolymer, and a triblock copolymer, and a
polyether block amide (e.g., a PEBAX.RTM. material). The outsole
may be formed of one or more materials including, without
limitation, elastomers (e.g., thermoplastic polyurethane),
siloxanes, natural rubber, and synthetic rubber.
[0030] Referring to the embodiment illustrated in FIGS. 2 and 3,
the upper 105 includes a first or planum portion 205 (i.e., a
portion of the upper that directly covers and/or engages a portion,
e.g., a majority or entire portion, of a bottom side of a wearer's
foot) and a second or dorsum portion (i.e., a portion of the upper
that directly covers and/or engages a portion, e.g., a majority or
entire portion, of an upper side of the wearer's foot). The planum
portion 205 is coupled (e.g., connected) to the dorsum portion 210
at a coupling location (e.g., via stitching and/or a coupling
member 160 as described herein).
[0031] The planum portion 205 may further include subportions
extending from the rear foot region 115 to the forward foot region
125 to generally cover the heel and planum areas of the foot, as
well as to cover portions of the lateral and medial sides of the
upper. As depicted in FIG. 3, the planum portion 205 includes a
heel cup 305 and a planum support 310 extending forward from the
heel cup. The planum portion 205 further includes lateral and
medial side portions 315 each of which extends forward from the
heel cup 305 to an edge 320 that is located proximate the
transition from the instep 145 to the toe cage 150 of the upper
105. In addition, the lateral and medial side portions 315 are the
same or similar in shape and configuration. Each side portion 315
further extends upward from the planum support 310 so as to extend
over a section of the dorsum portion 210 at the instep 145, and
each side portion 315 also includes a plurality of fastener
engaging elements 325 that extend from an upper edge of each side
portion 315. Each fastener engaging element 325 can comprise a
looped section of material that includes an opening configured to
receive and retain a portion of the fastener 127. The planum
support 310 extends the length of the upper 105 and defines a lower
surface of the upper that couples with the sole structure 110.
[0032] The dorsum portion 210 extends from the forward footwear
region 125 to the intermediate footwear region 120 and defines the
toe cage 150 as well as most of or the entire instep 145, including
the tongue 147, of the upper 105. The dorsum portion 210 further
defines portions of the lateral and medial side portions 215 that
define part of the toe cage 150 and extend so as to at abut and/or
at least partially overlap with each of the lateral and medial side
portions 315 of the planum portion 205. As described herein, the
dorsum portion 210 couples with the planum portion 205 such that
the lateral and medial side portions 315 are secured with lateral
and medial side portions 215 and the planum portion 205 at the
forward footwear region 125 further secures with the planum support
310.
[0033] The planum portion 205 may be connected to the dorsum
portion 210 in a seamless and/or stitchless manner. In an example
embodiment, each side 315 of the planum portion 205, including the
edge 320, overlaps (or abuts) an edge or portion of a corresponding
side 215 of the dorsum portion 210, where the overlapping (or
abutting) parts of the dorsum and planum portions are secured in
any suitable manner (e.g., via adhesive, stitching, etc.). For
example, each planum portion side 315 can be secured at or near its
edge 320 to the underlying dorsum portion side 215 via a suitable
type of stitch (e.g., a zig-zag flatlock stitch). Further, a
suitable coupling member 160 can be provided to further couple the
planum and dorsum portions together at or near the edge 320. The
coupling member 160 can comprise a fabric tape member (e.g., BEMIS
seam tape, available from Bemis Associates, Inc., Shirley, Mass.),
where the coupling member 160 further can be used to cover the edge
320. In example embodiments, the coupling member 160 comprises
fabric similar to fabric and/or other materials that form the upper
(e.g., polyester, spandex, etc.). While the coupling member 160 is
shown in the figures as being disposed on an external side of the
upper 105, a similar coupling member can also be provided
internally within the upper 105 at the join or connection between
the portions 205, 210.
[0034] Thus, the coupling member 160 is applied such that the
coupling member bridges the connection between the portions 205,
210, covering the stitching. The coupling member 160 can be
effectively secured to these portions of the upper 105 by applying
heat to the coupling member 160 to seal the seam. With this
configuration, the coupling member 160 provides a seamless
connection that minimizes and/or eliminates the friction caused by
conventional (exposed) seams. That is, a seamless connection is
provided because the coupling member 160 creates a generally
uninterrupted and/or continuous surface along the interior surface
and/or exterior surface of the upper 105.
[0035] The planum support 310 of the dorsum portion 205 further
includes an edge 312 (e.g., at the forward footwear region 125
and/or part of the intermediate footwear region 120) that secures
to a lower portion (e.g., edge portions) of the planum portion 210
in any suitable manner (e.g., stitching, adhesive bonding,
etc.).
[0036] In alternative embodiments, the planum portion 205 and
dorsum portion 210 may be connected at any or all locations without
stitching, instead utilizing a thermoplastic film that traverses
the seams between adjacent portions, bonding the portions 205, 210
together (e.g., utilizing SEWFREE tape, available from Bemis
Associates, Inc., Shirley, Mass.). In still further alternative
embodiments, ultrasonic welding could be utilized. In an
embodiment, individual pieces are joined by ultrasonic welding, and
the weld is covered by a strip of heat sealable film.
[0037] In any of the described embodiments, the coupling member(s)
used to secure the dorsum and planum portions together at various
locations can have any suitable shapes and/or configurations, such
as curved or undulating shapes to track the contours of the
internal or external surfaces of the two portions of the upper.
[0038] The upper 105 (the planum and/or dorsum portions) may
comprise any materials suitable for its described purpose. In
particular, the upper 105 may be formed of material capable of
forming the contours of the upper as well as any structures located
on internal and/or external surfaces of the upper. The material is
a thermoformable, textile laminate (also referred to herein as a
fabric laminate) comprising a plurality of layers including one or
more fabric (textile) layers, one or more foam layers, and at least
one structural support layer disposed internally within the upper
(i.e., located between two or more layers within the plurality of
layers forming the upper), where the fabric laminate is capable of
being shaped via compression molding.
[0039] The one or more fabric layers provided in the fabric
laminate can comprise any suitable textile, herein defined as
fabrics and other manufactured products made from strands such as
fibers, filaments, and yarns. By way of example, the textiles
include knit, woven, nonwoven, embroidered, and braided
constructions. The strands forming the fabric may include hard
yarns or resilient yarns possessing stretch and recovery
characteristics. Specifically, the hard yarns may include any one
or combination of compounds selected from the group consisting of
polyurethanes, polyesters (e.g., polyethylene terephthalate),
polyolefins (e.g., polyethylene and polypropylene), polyamides
(e.g., aliphatic or aromatic polyamide materials, such as nylon),
and any suitable combinations or copolymers thereof. Regarding
elastic yarns, the strands include elastomeric materials such as a
polyester-polyurethane copolymer commercially available under the
names elastane, LYCRA and SPANDEX.
[0040] A fabric layer can further be formed of synthetic or natural
leather or may even further comprise a plurality of layers (e.g., a
plurality of layers comprising waterproof and breathable
properties, such as fabric layers commercially available under the
name GORETEX). The fabric layers can include elastomers that
provide any suitable degree of stretch (e.g., two way stretch or
four way stretch) at any one or more locations of the upper.
[0041] The fabric layers may possess any thickness suitable for its
described purpose. In example embodiments, the fabric layers can
have thicknesses in the range of about 0.25 mm to about 4 mm, e.g.,
about 0.50 mm to about 3 mm.
[0042] The one or more foam layers provided in the fabric laminate
can comprise any suitable one or more type(s) of open and/or closed
cell foam materials that provide adequate cushioning and comfort
for the intended purpose. In particular, an open-celled,
thermoplastic foam may be utilized. Some examples of types of foam
materials suitable for use in forming the upper include, without
limitation, polyolefins (e.g., polyethylene or polypropylene) foam
materials, ethylene vinyl acetate (EVA) foam materials and
polyurethane (PU) foam materials. The foam materials can have a
thickness that is greater than the fabric materials. In example
embodiments, the foam materials can have thicknesses in the range
of about 1 mm to about 10 mm, e.g., about 2 mm to about 8 mm (e.g.,
about 3 mm to about 6 mm). Foam layers can vary in thickness
depending upon where such foam layers are located along the upper.
For example, a foam layer provided in a laminate of the planum
portion 25 can have a thickness that is greater than, e.g., the
thickness of a foam layer provided in the dorsum portion 210 of the
upper. In an example embodiment, a foam layer that is about 6.0 mm
thick is provided between fabric layers in the planum portion 205
that serves as a cushioning foot bed for the wearer's foot.
[0043] The one or more internal structural support members provided
within the fabric laminate that forms the upper can be formed of
any suitable type(s) materials that deform during the compression
molding process and provide structural support for the upper at the
location(s) in which the support members are provided once the
material cools. In particular, the materials used to form the
internal structural support members can be formed so as to have a
hardness value (e.g., as measured on a Shore A hardness scale, a
Shore A hardness) that is greater than the hardness value (e.g.,
Shore A hardness) of the materials used to form the foam and fabric
layers of the fabric laminate. Some examples of materials that can
be used to form the internal structural support members include,
without limitation, polyurethanes, polyolefins, polyamides (e.g.,
nylon), ethylene vinyl acetate (EVA), etc. In example embodiments,
one or more internal structural support members are formed from a
thermoplastic polyurethane (TPU) material, such as a TPU material
commercially available from Chemex Company Ltd. During the
formation of the fabric laminate, the internal structural support
member can be formed from a flat sheet that is contoured during the
compression molding process. Alternatively, the internal structural
support member can be formed from starting materials comprising a
powder composition that is fused and hardened into a single,
unitary member either prior to or during the compression molding
process. The internal structural support member can have a
thickness in the range of about 0.2 mm to about 2.0 mm (e.g., a
thickness of about 1.0 mm).
[0044] As noted herein, the fabric laminate that forms the upper
comprises a plurality of layers and can include any selected number
of layers, where different fabric laminates including different
types and/or numbers of layers can be provided at different
locations of the upper. For example, some locations of the upper
may include one or more internal structural support members while
other locations do not, thus changing the structural configuration
of the fabric laminate at different locations of the upper. As seen
best in FIG. 4, the shoe 10 includes an internal structural support
member in the form of an internal heel counter 420 located at the
heel end 130 (i.e., at the heel cup 305) of the upper. The heel
counter spans continuously from the lateral side to the medial side
of the upper, as well as from a point proximate the collar to a
point proximate the sole structure. The heel counter contours with
the heel cup, curving continuously from its upper edge to its lower
edge, as well as from its lateral edge to its medial edge.
[0045] It is noted that an internal structural support member can
also be provided at any other suitable locations (e.g., at the toe
cage 150) so as to add rigidity, hardness and/or support to the
upper 105 at such locations.
[0046] The compression molding process used to form the fabric
laminate of the upper comprises a method of molding in which the
molding material is first placed in an open, heated mold cavity.
The mold is closed with a top force or plug member, pressure is
applied to force the material into contact with all mold areas,
while heat and pressure are maintained until the molding material
has cured. The temperatures and pressures used in the compression
molding process will depend upon the materials used to form the
various layers within the fabric laminate, where softening of one
or more layers is required to ensure suitable adhesion of the
layers together during the compression molding process. In
particular, softening of the one or more layers comprises being
heated to a temperature that is lower than the melting point of the
materials forming the layers (e.g., the softening temperature is at
least about 20.degree. C. lower than the melting point of the
materials forming the layers). Example softening temperatures used
during the compression molding process can be in the range from
about 130.degree. C. to about 200.degree. C. (e.g., about
140.degree. C. to about 190.degree. C.).
[0047] Example fabric laminate layers used to form portions of the
upper for the shoe depicted in the figures include a series of
layers as follows (from internal or foot facing side to external
side of the upper): fabric layer/foam layer/reinforcing fabric
layer/foam layer/fabric layer. For fabric laminate layers that
include an internal structural support layer, the internal
structural support member can be provided as a layer disposed at
any location within the fabric laminate such that at least one
layer is located on one side of the internal structural support
layer and at least one layer is located on the other side of the
internal structural support layer.
[0048] Referring to FIG. 4, an example embodiment is depicted
showing the formation of a fabric laminate used to form the heel
end 130 of the upper 105. The fabric laminate 405 used to form the
upper 105 at the heel end 130 includes a plurality of layers that
are oriented or "stacked" in the following alignment (from interior
or upper cavity/foot-facing side to exterior side of upper, or from
right to left as shown in FIG. 4): (inner) fabric layer 408/foam
layer 410/reinforcing fabric layer 415/internal structural support
member layer 420/foam layer 410/(outer) fabric layer 408. However,
the internal structural support member layer 420 can be provided at
any other location within the plurality of layers (i.e., between
the inner and outer fabric layers 408). The inner and outer fabric
layers 408 can be formed of the same or different materials. In
addition, the foam material layers 410 can also be formed of the
same or different materials. The reinforcing fabric layer 415 can
be formed of the same or different type(s) of materials as the
inner and outer fabric layers 408. In further example embodiments,
the reinforcing fabric layer 415 can further include one or more
additional foam layers (e.g., including a foam layer/fabric layer
laminate defining the reinforcing layer 415, or a foam layer/fabric
layer/foam layer laminate defining the reinforcing layer 415).
[0049] In an example embodiment, one or more of the fabric layers
408, 415 can comprise polyester and/or an elastomer material (e.g.,
elastane), the foam layers 410 can comprise an open cell PU or EVA
foam material, and the internal structural support member layer 420
can comprise a TPU plastic material. In a further example
embodiment, one or both the inner and outer fabric layers 408 can
comprise a fabric material including about 85% polyester and about
15% elastane (weight 215 g/m.sup.2), and the reinforcement fabric
layer 415 can comprise a fabric including about 79% polyester and
about 21% elastane (weight 210 g/m.sup.2). The outer and inner
fabric layers may possess similar or different properties such as
elongation properties. By way of example, the outer fabric layer
may possess a greater degree of elongation or elasticity along one
or more dimensions (e.g., along a length and/or width of the outer
fabric layer) in comparison to the inner fabric layer.
Alternatively, the inner fabric layer may possess a greater degree
of elongation or elasticity along one or more dimensions (e.g.,
along a length and/or width of the inner fabric layer) in
comparison to the outer fabric layer.
[0050] The compression mold equipment or apparatus used to secure
the plurality of layers together to form the fabric laminate 405
includes a pair of molding portions 402, 404. In particular, the
mold portions include a first or female molding portion 402 that
includes a generally curved, concave surface and a second or male
molding portion 404 that includes a generally curved, convex
surface that is complementary to the concave surface of the female
molding portion 402 so that the male molding portion 404 is
configured to be received by and engage with the female molding
portion 402. The compression mold apparatus is configured to shape
the layers 408, 410, 425, 420 as they are pressed together between
the female and male molding portions 402, 404 during the
compression molding process. The molding of the layers can be
performed in a single compression mold operation (e.g., combining
all layers in their proper orientation or "stacked" positions and
then pressing together within the mold apparatus) or in a plurality
of compression mold operations (e.g., press two or more layers
together in the mold, following by pressing further layers
together, etc. until the final fabric laminate is formed). The
final fabric laminate formed by the compression mold apparatus will
have a contour that is suitable for the location in which the
fabric laminate is to be utilized for forming the upper. For
example, each of the planum portion 205 and dorsum portion 210 can
be formed with different compression molding portions such that
they are formed of fabric laminates having the configuration shapes
and contours as depicted in FIGS. 2 and 3.
[0051] An example compression molding process for forming a fabric
laminate for the upper 105, in particular the heel cup 305 of the
planum portion 205, is described with reference to FIG. 4 and the
flowchart of FIG. 5. The materials used to form the layers are
initially prepared. In particular, at 505, the material used to
form the internal structural support member 410 is prepared by
either die cutting a portion of a flat blank of the TPU plastic
material or forming a solid TPU portion from a powder composition
(heating/fusing the powder composition to form a unitary solid
member that is generally flat). The material layer (the heel
counter 420) can have a thickness of about 1 mm. At 510, each inner
and outer fabric layer 408 is secured, via hot melt lamination, to
a corresponding foam layer 410.
[0052] The other materials used to form the various layers can also
be prepared, as necessary (e.g., by cutting each material from a
blank to the appropriate size/dimensions for the mold apparatus).
Each material portion forming the layer can be initially configured
as a generally flat sheet of material. For example, in an
embodiment in which the reinforcement fabric layer 415 includes
both a fabric layer at least one additional foam layer (e.g.,
foam/fabric laminate, or foam/fabric/foam laminate), the
reinforcement layer 415 can be prepared accordingly. For example,
the reinforcement layer 415 can include a foam/fabric/foam laminate
in which each foam layer is about 3 mm. The mold portions 402, 404
can further be heated to suitable temperatures for the mold
process.
[0053] At 515, the inner fabric layer 408, foam layer 410 and
reinforcement fabric layer 415 can be compression molded together
to form a first package of combined layers in the following manner.
The combined (via hot melt lamination) inner fabric layer 408 and
foam layer 410 are placed against mold portion 404 (with the fabric
layer 408 adjacent the mold portion 404). The reinforcement layer
can have an adhesive sprayed on one or both of its sides and
adhered against the foam layer 410. The mold portions 402 and 404
can be pressed together at a sufficient temperature (e.g., a
temperature of the mold portions of about 190.degree. C., imparting
a sufficient heat to the layers such that the layers are at a
temperature of about 150.degree. C.) and for a sufficient time
period (about 160 seconds). The first package of molded components
can then be cooled for about 2 minutes and/or until reaching
ambient temperature (about 24.degree. C. to about 28.degree. C.)
and removed from the mold portions.
[0054] At 520, the internal structural support member layer 420 is
adhered to the combined outer or external fabric layer 408/foam
layer 410 to form a second package of combined layers in the
following manner. The combined (via hot melt lamination) external
fabric layer 408 and foam layer 410 are placed against mold portion
402 (with the fabric layer 408 adjacent the mold portion 402). The
internal structural support member layer 420 is heated for a
suitable time (e.g., about 10 seconds) and at a sufficient
temperature (e.g., about 150.degree. C.) to soften the layer 420,
and it is then pressed against the foam layer 410 of the combined
external fabric layer 408/foam layer 410, resulting in layer 420
adhering to layer 410. The internal structural support member layer
420 is suitably aligned with the foam layer 410 before it is
pressed against it so as to ensure that the internal structural
support member 420 is aligned in the proper orientation and
location of the fabric laminate 405 to be formed (and thus properly
aligned within the heel cup 305 of the upper 105). In an example
embodiment, the foam layer 410 can be provided with any suitable
alignment indicators (indicia, one or more indentations, etc.) to
facilitate appropriate alignment of the support member layer 420
against the foam layer 410.
[0055] At 525, the first package of the combined inner fabric layer
408/foam layer 410/reinforcement layer 415 is placed in mold
portion 404 (with fabric layer 408 adjacent mold portion 404),
while the second package of the combined outer fabric layer
408/foam layer 410/structural member layer 420 is placed in mold
portion 402 (with fabric layer 408 adjacent mold portion 404). The
mold portions 402, 404 are pressed together to compression mold all
of the various layers together forming the fabric laminate 405. In
an example embodiment, the compression molding process to secure
all layers together (step 525) can be carried out at a temperature
of the mold portions of about 190.degree. C., imparting a
sufficient heat to the layers such that the layers are at a
temperature of about 150.degree. C., and at a time of about 160
seconds. The molded fabric laminate 405 can then be cooled for
about 2 minutes and/or until reaching ambient temperature (about
24.degree. C. to about 28.degree. C.) and removed from the mold
portions. Optionally, an additional mold piece can be used that is
contoured similar to the contours of the mold portions 402, 404 and
to which the fabric laminate 405 is held against for a suitable
time period to ensure the fabric laminate 405 maintains its molded
shape during cooling.
[0056] Thus, the compression molding process forms a contoured
portion of the upper 105 that is shaped in the form of the mold
portions and which holds and maintains its shape. In particular,
the planum portion 205 and/or dorsum portion 210 can each be formed
via the compression molding process, with the same or different
number and/or types of material layers. For example, the planum
portion 205 can be formed via the compression molding process
including the inner structural support member 420 which is an
internal heel counter for the shoe, where the support member/heel
counter 420 has a curved, general U-shape and is provided between
the inner and outer fabric layers 408 of the fabric laminate 405
that forms a part of the upper 105 at the curved (rounded) heel cup
location 305. The internal structural support member 420 (defining
the internal heel cup) defines an internal reinforcing element for
the upper that possesses rigidity that is equal to or greater than
that of both the inner and outer fabric layers as well as most or
all of the other layers (e.g., foam layers and reinforcing fabric
layer) within the fabric laminate. In particular, the internal
structural support member forms a reinforcing plate that provides
additional support to the ankle, functioning as an internal heel
counter.
[0057] Conventional shoes provide a heel counter that is external
to the shoe (i.e., located adjacent an outer surface portion and
around the heel cup of the upper). The inner structural support
member/heel counter 420 of the present invention is "hidden" (i.e.,
not externally exposed) but provides the same or similar benefits
as a conventional heel counter in that it functions to strengthen
the heel area of the upper, stabilize the user's heel inside the
shoe, provide support around the user's ankle and/or control and
stabilize the user's heel inside the shoe and to minimize excessive
supination or pronation of the foot. As previously noted, the
internal structural support member can be formed of any suitably
rigid materials that can have a hardness (e.g., a Shore A hardness
value) that is greater than any of the other fabric or foam layers
within the fabric laminate forming portions of the upper. The
support member/heel counter 420 can be flexible, semi-rigid or
rigid and can be formed, e.g., from a suitable thermoplastic
elastomer material such as EVA or PU so as to provide suitable
rearfoot stability, preventing injury and prolonging the life of
the article of footwear.
[0058] As previously noted, one or more internal structural support
members can also be provided at other locations of the upper, e.g.,
at the toe cage 150 (e.g., to protect the user's toes) and/or along
one or both of the lateral and medial sides 135 of the upper 105
(e.g., to provide support at different lateral and/or medial side
locations of a user's foot). An example embodiment of the upper 105
is depicted in FIG. 6 in which internal structural support members
include the internal structural support member 420 located at the
heel cup of the upper and defining an internal heel counter, an
internal structural support 610 provided along a side surface
(e.g., lateral side and/or medial side) of the upper 105 to provide
a desired level of support, stiffness and/or rigidity at the side
surface, and an internal structural support 620 provided at a
portion of the toe cage 150 of the upper 105 to provide additional
support, stiffness and/or rigidity at the toe cage (e.g., to
provide a harder, more stiff structural support that absorbs forces
and protects the wearer's toes against impact from a surface or
object). The compression molding process facilitates formation of
the upper with one or more internal structures (either continuous
or separated from each other within the upper) that are non-planar
and contour along one or more portions of the upper. For example,
as previously noted, the internal heel counter/structural support
420 can have a generally curved or U-shape that extends around the
heel cup section 130 of the upper 105 to the lateral and/or medial
sides of the upper. The toe cage structural support 620 can also
have a curved configuration that conforms with a portion of the toe
cage section 150 at the front or forefoot end of the upper 105
(e.g., a portion of the support 620 curves around the upper at the
end of the wearer's toes as shown in FIG. 6). The internal side
support 610 can also have a slightly rounded or non-planar
configuration that conforms to the contour of the side of the upper
105.
[0059] During compression molding of the different portions of the
upper can be achieved using any selected number of different mold
portions for the mold apparatus to achieve the varying contours of
the upper portions (e.g., the contours of the dorsum and planum
portions 205, 210 of the upper as depicted in FIGS. 2 and 3). In
addition, certain layers the form the fabric laminate (e.g., a
laminate 405) can have different dimensions and/or shapes depending
upon the configuration of the upper portion to be compression
molded. In the embodiment depicted in the figures, the inner
structural support member/heel counter 420 (and/or any of the other
internal structural support members, such as supports 610 and 620)
has a starting shape, dimensions and configuration that differs
from the other fabric and foam layers since the counter 420 formed
within the laminate 405 is only provided at the heel cup location
150, whereas other layers (e.g., the inner and outer fabric layers
408) extend further in dimensions along the fabric laminate 405
forming the planum portion 205.
[0060] The formation of the upper in this manner results in a heel
cup 305 defined by the planum portion 205 that is seamless. This
differs from conventional footwear, which typically includes a seam
(e.g., a welded seam or a stitched seam) within the heel cup. For
example, a conventional heel cup includes a vertical seam along the
connection between two heel halves (lateral and medial halves) and
a longitudinal seam along the connection between the two halves of
the footpad. In contrast, the heel cup 305 does not include a seam.
Instead, the heel cup 305 is a unitary structure shaped to define a
seamless, unitary heel cup. In a further embodiment, the entire
planum portion 205 can be seamless, with the heel cup 305, and the
planum support 310 and lateral and medial sides 315 forming a
unitary and/or one-piece structure.
[0061] Similarly, the dorsum portion 210 can also be a unitary,
one-piece and seamless structure. In other words, the toe cage 150
and inseam 145 (defined by the dorsum portion 210) can both be
seamless.
[0062] The compression molding process can further include mold
portions having patterned depressions and/or protrusions that, when
forming the fabric laminate, define a corresponding "mirror image"
pattern of depressions and/or protrusions along a surface of the
fabric laminate that defines an exterior surface portion of the
upper. This facilitates the formation of macrostructure (the heel
curvature) and/or microstructures on inner and/or outer surfaces of
the upper. For example, the heel cup 305 of the upper 105 can
include an external surface pattern 170 that forms an uneven
contour of indentations and/or raised ridges (e.g., a pattern 170
having generally concave depressions, such as polygonal or diamond
shaped depressions). The pattern 170 can further be formed on the
outer surface of the outer fabric layer 408 or, alternatively, on
another layer formed over the outer fabric layer 408. For example,
a further reinforcement layer 168 (shown in FIG. 1A) can be
provided (e.g., a plastic material layer) that includes the pattern
170 disposed on it. In this embodiment, a coupling member 180
(e.g., fabric tape, as shown in FIG. 1A) can be provided at the
join or connection between edges of the reinforcement layer 168 and
the underlying portion of the upper (e.g., to provide a seamless
and frictionless join or connection at these locations of the
upper).
[0063] For example, protrusions can be formed at outer surface
portions of the upper, via the compression molding process, that
provide abrasion resistance or impact protection in specified areas
of the upper. In addition, the protrusions may define contact areas
configured to improve contact with a ball during game play (e.g., a
soccer ball, kickball, etc.). When disposed on the inner surface of
the upper, the protrusions can function as spacers to create air
gaps or channels between the upper and the foot of the user,
enabling airflow within the channels. The protrusions are
integrated into the upper, being formed as the result of the shape
of the mold portions. The protrusions may be any size and shape
suitable for their described purpose, and may be disposed in any
predetermined pattern along a portion of the upper, or along the
entire upper.
[0064] In other example embodiments, one or more layers forming the
fabric laminate (which forms a portion of the upper) can include a
patterned structure (e.g., protrusions and/or depressions) so as to
function as an auxetic material. Generally, auxetics are materials
that have a negative Poisson's ratio such that, when stretched, the
auxetic materials become thicker perpendicular to the applied
force. Imparting auxetic features within one or more layers (e.g.,
fabric, foam and/or internal structural support member layers) can
provide the effect of enhancing the mechanical properties such as
high energy absorption characteristics and greater ability to
stretch without tearing/fracturing.
[0065] After the upper 105 is formed, the upper is coupled (e.g.,
mounted) at its lower end portion(s) to the sole structure 110 in
any suitable manner, e.g., via an adhesive, welding (e.g.,
ultrasonic welding), etc.
[0066] Thus, the present invention facilitates the formation of an
article of footwear in which the upper can be formed in one or more
portions via a compression molding process, where an internal
structural support member (e.g., an internal heel counter) can be
provided within and between two or more layers of the upper to
enhance the structural support at different locations of the
upper.
[0067] While the invention has been described in detail and with
reference to specific embodiments thereof, it will be apparent to
one skilled in the art that various changes and modifications can
be made therein without departing from the spirit and scope
thereof. For example, while the example embodiments depicted in the
figures show an article of footwear (shoe) configured for a right
foot, it is noted that the same or similar features can also be
provided for an article of footwear (shoe) configured for a left
foot (where such features of the left footed shoe are reflection or
"mirror image" symmetrical in relation to the right footed
shoe).
[0068] The upper 105 can be formed of any one or more materials
suitable for its described purpose, including conventional
materials (e.g., woven or nonwoven textiles, knit textiles,
leather, synthetic leather, rubber, etc.). The specific materials
utilized to form the upper are generally selected to impart
wear-resistance, flexibility, air-permeability, moisture control
and/or comfort to the user wearing the shoe 10.
[0069] Further, the upper 105 may possess any dimensions
(size/shape) suitable for its described purpose. For example, the
upper 105 may possess a "high top" configuration, in which a heel
end 130 of the upper extends over and/or above at least a portion
of a user's ankle. Alternatively, the upper 105 may possess a "mid
top" configuration (in which the upper extends to slightly below or
at the user's ankle), a low top configuration, or any other
suitable configuration. The upper 105 can be coupled to the sole
structure 110 in any suitable manner (e.g., via a strobel or, when
no strobel is required due to an enclosed or sock-like
configuration of the upper, via direct connection between a lower
portion of the upper and an upper portion of the sole structure),
where such coupling can be achieved in any conventional and/or
other suitable manner (e.g., via any form of adhesion or bonding,
via stitching, via one or more types of fasteners, etc.).For
example, the upper can be completely or partially formed with
fabric laminate portions via a compression molding process. Any
selected number and/or types of material layers can be used to form
a fabric laminate at portions of the upper. The upper can be formed
as a single, integral piece or component or, alternatively, as a
plurality of pieces or components that are secured together via
techniques as described herein. The upper can be provided with a
single internal structural support member or a plurality of such
support members at one or more locations of the upper.
[0070] Thus, it is intended that the present invention covers the
modifications and variations of this invention provided they come
within the scope of the appended claims and their equivalents. It
is to be understood that terms such as "top", "bottom", "front",
"rear", "side", "height", "length", "width", "upper", "lower",
"interior", "exterior", and the like as may be used herein, merely
describe points of reference and do not limit the present invention
to any particular orientation or configuration.
* * * * *